Initial Print Date:05-01 Revision Date:Subject PageConnector
Contact
Kit................................................................................3BMW
Plug System
Abbreviations...............................................................
5Plug System
D1.5/D2.5..............................................................................6Plug
System
JPT/MDK/DFK.....................................................................10Plug
System Elo/Elo
Power.......................................................................12Plug
System
MQS/MPQ............................................................................14Miscellaneous
Connectors........................................................................22Solderless
Terminals and
Connectors.......................................................25Electrical
Repair Kit
IV...............................................................................
26Cable
Stripping.........................................................................................27Crimping...................................................................................................28Prepackaged
Wiring Repair
Sets..............................................................
30Breakout Boxes and V
Cables................................................................33Tester
and Adapter Set for
Relays.............................................................36Review
Questions.....................................................................................41Table
of ContentsBreakout Boxes and Connectors2Breakout Boxes and
ConnectorsBreakout Boxes and ConnectorsModel: AllProduction Date:
AllObjectiveAfter completion of this module you will be able to:
Recognize and distinguish the various Electrical Repair Kits. Use
the Connector Removal Kit. Recognize the plug configurations and
disassemble them properly. Repair wiring harnesses and connectors.
Choose the proper Breakout Box and V cable for testing. Use the
relay testing tool.3Breakout Boxes and ConnectorsBreakout Boxes and
ConnectorsCONNECTOR CONTACT REMOVAL
KITTheconnectorcontactremovalkitprovidestools for the disassembly
of connectors.
Properuseofthesetoolsenablethetechniciantoaccesswiringconnectorsforrepairsequaltofactory
quality.AlwaysrefertothelatestServiceInformationBulletins(Group04)foruptodateinformationregarding
new tools.The Connector Contact Removal Kit is used for: Releasing
round plug housings. Releasing relay carriers. Pressing out
contacts. Pulling out indicator lamps.Socket and Spring
ContactsSocket and Spring contacts compress the springs while the
connector is pushed fromthe housing.12510195.bmp
12510196.bmp12510194.bmpCurrent P/N 88 88 6 611 1504Breakout Boxes
andConnectorsFlatspringcontactsdepressthespringallowingtheconnectortobepushedorgentlypulled
from the connector housing.Instrument Cluster Illumination Bulb
Holder Removal SocketThe backlighting illumination bulbs are
removedfrom the cluster by placing square head of
thesocketonthebulbholderandturning90ocounter
clockwise.Thebulbremovalsocketisusedonallinstru-ment clusters.Relay
Holder Disengaging ToolThis tool allows the relay holder (2) to
disengagethe relay connector (1).12510197.bmp
12510198.bmp12510199.bmp125101100.bmp5Breakout Boxes and
ConnectorsCircular Connector Lock DisengagerThese tools unlock the
circular connector
hous-ingsallowingtheindividualconnectorstoberemoved.The various
sizes are reflected in the part num-bers4 pin = 61 1 1417 pin = 61
1 14210 pin = 61 1 14512 pin = 61 1 14325 Pin = 61 1 144
125101102.bmp125101103.bmp 125101104.bmp 125101105.bmpBMW Plug
System AbbreviationsD 1.5/2.5 Round contacts of 1.5mm or 2.5mm
diameterMDK 3 Plus Miniature double flat spring contactJPT ELA
Junior Power Timer flat spring contacts with strand sealingDFK ELA
Double flat spring contacts with strand sealingElo Electronic
contacts with and without strand sealingManufacturer: SiemensElo
Power Electronic contacts for heavy loads with and without strand
sealingManufacturer: SiemensMQS Micro Quadlock System electronic
contacts with and without strandsealing Manufacturer: AMPMPQ Micro
Power Quadlock electronic contacts for heavy loads with and without
strand sealingManufacturer: AMP 6Breakout Boxes and
ConnectorsCircular plug 13 Pin System D2.5 Carefully pull off the
rubber grommet (1). Pull the lock retainers (2) outward (direction
of arrows) to allow the lock notch to disengage. Pull the inner
section (3) upward as shown in the illustration until the lock
notches (4) arein the released position of the lock retainers (5)
and use the appropriate size spring contact and remove the
connector from the housing. Circular Plug 7-8 Pin System D2.5 Pull
off the rubber boot (1). Push the retaining lugs (2) of the inner
connector section 3 inward carefully to disengagethe lock notch.
Push the inner connector section (3) in the direction of the arrow
in the illustration until the retaining lugs (2) are in the
recessed notch (4) and use the appropriate sized springcontact tool
andremove the connector from the housing.125101106.bmp
125101107.bmpPlugSystem D1.5/D2.5125101108.bmp125101109.bmpCircular
Plug 4-7-10-12-25 Pin System D1.5/D2.5 Insert the appropriate
unlocking tool (determined by the number of pins) into the
connector. The connector is unlocked when the lock tab (3) is in
the unlocked position (1).The connector is locked when the lock tab
(3) is in the locked position (2).Use the appropriate sized spring
contact and remove connector from the housing.125101116.bmp
125101117.bmp7BreakoutBoxes and ConnectorsCircular Plug 20 Pin
System D2.5 With the boot pulled back, press the lock tabs (1) of
the inner connector section (2)inward. Simultaneously, rotate the
inner connection section (2) counter clockwise to allow the lock
tabs (1) to engage in the unlocked position and use the appropriate
sized spring contact and remove connector from the
housing.125101110.bmp 125101111.bmpIn-line Plug 8-, 12 Pin System
D2.5 Slide the upper section (1) and the lower section (2) of the
connector in opposite direc-tions to unlock the connector. Using
special tool 61 1 132 press the spring latch down and pull the
connector (3) fromthe housing.In-line Plug 15 Pin System D2.5 Pull
the outer connector section (1) slightly outward in the area of
lock tabs (2). Simultaneously, slide the inner connector section
(3) in the direction of the arrow to theunlocked position. Use the
appropriate sized spring contact and remove connector from
housing.125101118.bmp 125101119.bmp8Breakout Boxes and
Connectors125101112.bmp 125101113.bmp9Breakout Boxes and
ConnectorsIn-line Plug 20 Pin System D2.5 Pull locking slide (1)
completely out of connector (2). Using special tool 61 1 132 press
the spring latch down and pull the connector from
thehousing.125101114.bmp125101115.bmpIn-line Plug 30 Pin System
D2.5 Pull the outer section (1) slightly outward in the area of
lock tabs (2). Simultaneously, slide the inner connector section
(3) in the direction of the arrow to the unlocked position. Use the
appropriate sized spring contact and remove connector from
housing.125101120.bmp 125101121.bmp10Breakout Boxes and
ConnectorsPlug System JPT/MDK/DFKIn-line plug 2 Pin System JPT ELA
Press lock (1) in direction of arrow and slide plug forward. Press
lock (1) downward and slide out to one side. Unlock contact with
special tool 61 1 136 and pull out cable (2) and contact towards
rear.125101138.bmp2125101140.bmp 12510139.bmp125101159.bmp
125101158.bmpIn-line plug 2 Pin System MDK 3 plus 2.8 Unlock lock
(1) on outside at arrester hook and slide out lock (1) side. Unlock
contact with special tool 61 1 136 and pull out cable (2) and
contact towards rear.211Breakout Boxes and ConnectorsIn-line plug 4
Pin System DFK ELA Press arrester hook in direction of arrow
andremove lock (1). Unlock contact with special tool 61 1 136and
pull cable and contact out towards rear.Installation Instructions
If necessary, slide lock must also be unlocked with screw
driver.125101162.bmp125101160.bmp125101161.bmpNotes:12Breakout
Boxes and ConnectorsPlug System Elo/Elo-PowerIn-line plug 4-,10 Pin
System Elo Slide connector lock (1) off of main connector body.
Push the lock tab of the connector being removed down (3) with pin
or small screwdriver in the primary lock slot(4) and pull the wire
out (5) to the secondary lock position (6). Push the lock tab down
again in the secondary lock position and remove wire
completely.125101129.bmp 125101130.bmp 125101131.bmpIn-line Plug
3-,6 Pin System Elo-Power 2.8 Press unlocking hook (1) in direction
of arrow and disengage. Then unlock locking hook (2) and remove
lock. Press down arrestor hook (3) with screwdriver and pull out
cable with contact towardsrear.125101136.bmp
125101137.bmp13Breakout Boxes and ConnectorsIn-line Plug 6-,50 Pin
System Elo Unlock lock (Fig. 14/1). Unfasten cable clip (Fig.
14/2). Slide connector lock (1) off of main connector body (2)
(Fig. 14/3). Push the connector plate (3) out of connector shell
using a small screwdriver through hole on end of connector body
(Fig. 14/4). Push the lock tab of the connector being removed
down(6) with pin or small screwdriver in the primary lock slot (7)
and pull the wire out to the secondary lock position (8)(Fig.
14/5). Push the lock tab down again in the secondary lock position
and remove wirecompletely (Fig. 14/6).Fig. 14/1Fig. 14/2Fig.
14/3Fig. 14/4Fig. 14/5Fig.
14/6125101132.bmp125101135.bmp125101134.bmp125101133.bmp125101164.bmp125101163.bmp14Breakout
Boxes and ConnectorsPlug System MQS/MPQIn-line Plug 6-,8 Pin System
MQS Press lock (1) in direction of arrow and slide plug forward.
Press locking hook (2) downward and slide lock (1) out. Press down
arrester hook (3) with screwdriver and pull out cable with contact
towardsrear.3In-line Plug 2 Pin System MPQ 2.8 Press catch on
outside in direction of arrow and remove towards top. Press down
arrestor hook (1) with screwdriver and pull out cable and contact
(2)towards rear.125101165.bmp 125101166.bmp
125101167.bmp125101169.bmp125101168.bmp15Breakout Boxes and
ConnectorsControl Unit Plug 25-, 35-, 55-,83-,88 Pin Remove
phillips head screws (1) from connector.Gently pivot the connector
plate (2) with seal (3) out of the connector shell. Remove seal (3)
and pull connector plate lock (4) out of locked position. Using the
appropriate sized spring contact and remove connector (5) from
housing.125101122.bmp 125101123.bmp125101124.bmpIn-line Plug 24 Pin
Hybrid System MQS/MPQManufactured by AMP: The following contact
types without strand sealing can be fitted in the plug
hous-ings:MQS (Micro Quadlock System)MPQ, width 2.8 mm (Micro Power
Quadlock)MPQ, width 5.2 mm (Micro Power Quadlock)Socket Housing
Press locks (1) on cap (2) upwards on both sides. Detach cap from
contact carrier (3).Note:Detaching the cap releases the second-ary
lock of the socket contacts.125101143.bmp16Breakout Boxes and
Connectors Hold down retaining hook (1) of socket contact carrier
with a small screwdriver. Pull wire with socket contact in
direction of arrow as far as secondary lock (2).(Fig. 17/1) Hold
down retaining hook in secondary lock (1) again and pull cable with
socket contact (2) completely out of contact carrier (3). (Fig.
17/2)Pin Housing Press locks (1) on cap (2) upwards on bothsides.
Detach cap from housing carrier (3)(Fig. 17/3).Note:Detaching the
cap releases the secondary locks of the pin contacts in the
contactcarriers. Pull contact carrier (1) out of housing carrier(2)
(Fig. 17/4).The pin contacts are pulled of a contact carrier as
described under Socket Housing. Fig. 17/1Fig. 17/2Fig. 17/3 Fig.
17/4125101144.bmp125101145.bmp125101147.bmp 125101146.bmp17Breakout
Boxes and ConnectorsSocket Housing 42-,43 Pin Hybrid Systems
MQS/MPQ Open secondary locks (1) on socket housing. Press back
retaining hook of MQS contacts (2) with special tool 61 1 134 and
pull out cable with contact. Press back retaining hook of MPQ
contacts (3) with screwdriver or similar tool and pullout cable
with contact.Installation: Bend open retaining hook of contacts
gently before inserting into plug housing. To install contacts,
observe cavity numbers on reverse side of socket
housing.Manufactured by AMP: The following contact types without
strand sealing can be fitted in the sockethousings:MQS (Micro
Quadlock System)MPQ, width 2.8 mm (Micro Power Quadlock)MPQ, width
5.2mm (Micro Power Quadlock)125101171.bmp125101170.bmpSocket
Housing 2x27-, 2x27 Pin Hybrid System MQS/MPQ, Elo/Elo
PowerManufactured by Amp:The following contact types without strand
sealing can be fitted in the socket housings:MQS (Micro Quadlock
System)MQS, width 2.8 mm (Micro Power Quadlock)MPQ, width 5.2 mm
(Micro Power Quadlock)18BreakoutBoxes and Connectors Raise lock (1)
on housing (2). Push contact carrier (3) from rear out of
housing.Note:The second carrier is pushed out in the
sameway.Pushing out the contact carrier releases the secondary
locks of the secondary contacts.In-line Plug 30 Pin Hybrid System
MQS/MPQManufactured by Siemens:The following contact types without
strand sealing can be fitted in the socket housings:Elo (electronic
contact)Elo-Power 2.8 mm wide (electronic contact for heavy
loads)Elo-Power 5.2 mm wide (electronic contact for heavy
loads)Procedure for removing contacts are same as for other
Elo/Elo-Power Systems, refer to those instructions.Manufactured by
AMP: The following contact types without strand sealing can be
fitted in the plug hous-ings:MQS (Micro Quadlock System)MPQ, width
2.8 mm (Micro Power Quadlock)MPQ, width 5.2 mm (Micro Power
Quadlock)Socket Housing Raise lock (1) on housing (2). Push contact
carrier (3) from rear out of housing (2).Note:Pushing out the
contact carrier releasesthe secondary locks of the socket
contacts.Procedure for removing contacts are same as for other
Elo/Elo-Power Systems, refer to those
instructions.125101172.bmp125101173.bmp19Breakout Boxes and
ConnectorsPin Housing Contact 1...13 and 19...27. Raise locking
slide(1) on both sides (2) of housing and detach.Note:Detaching the
locking slide releases the secondary locks of the pin contacts.
Contacts 14...18 and 28...30. Pull slide (1) outward completely.
Raise lock (2) on housing. Pull contact carrier out of
housing.Note:Pulling out the contact carrier releases the secondary
locks of the pin contacts.Sockethousing5pin(HybridSystemMQS/MPQ)
Raise fastener (1) (slide) by way of retaininglug (2) and detach
from contact carrier (3).125101174.bmp 125101175.bmpSocket Housing
5-, 8 Pin System MQS/MPQManufactured by AMP: The following contact
types without strand sealing can be fitted in the
sockethousings:MQS (Micro Quadlock System)MPQ, width 2.8 mm (Micro
Power Quadlock)MPQ, width 5.2mm (Micro Power
Quadlock)125101176.bmp20Breakout Boxes and ConnectorsRemoving MPQ
contacts from radio plug: Press lock (1) in direction of arrow,
detach secondary lock (2) from radio plug. Feed special tool 61 1
135 past side of contact. Press special tool 61 1 135 in direction
of arrow. Pull wire (1) with socket contact out of radio
plug(2).Procedure for removing contacts are same as for other
Elo/Elo-Power Systems, refer to those instructions.Socket Housing 8
Pin (MQS) Raise fastener (1) (slide) by way of retaining lug (2)
and detach from contact carrier (3).Socket Housing (Radio Plug)
Hybrid system MQS/MPSManufactured by AMP: The following contact
types without strand sealing can be fitted in the plug
hous-ings:MQS (Micro Quadlock System)MPQ, width 2.8 mm (Micro Power
Quadlock)MPQ, width 5.2 mm (Micro Power
Quadlock)125101177.bmp125101148.bmp 125101149.bmp21Breakout Boxes
and ConnectorsRemoving MQS contacts from carrier Press lock (1) in
direction of arrow and pull housing (2) out of radio plug (Fig.
22/1). Press lock (1) in direction of arrow. Pull contact carrier
(2) out of housing (Fig. 22/2).Note:When the contact carrier is
pulled out, the secondary locks of the socket contacts
areraised.Procedure for removing contacts are same as for
otherElo/Elo-Power Systems, refer to those
instructions.125101151.bmpFig. 22/2125101150.bmpFig. 22/1Removing
MPQ contacts from contact carrier Remove contact carrier (1) with
MQS contacts from radio plug. Raise lock (2) on radio plug. Pull
contact carrier (3) out of radio plug (Fig. 22/3). Press lock (1)
in direction of arrow. Pull secondary lock (2) in direction of
arrow completely out of contact carrier (3) (Fig. 22/4). Press
special tool 61 1 135 on inside of contact into contact carrier(2).
Pull wire withsocket contact (1) out of contact carrier (2) (Fig.
22/5).Fig. 22/3 Fig. 22/4 Fig. 22/5125101155.bmp125101156.bmp
125101157.bmp22Breakout Boxes and ConnectorsFuse Strip Pull
appropriate fuse from fuse strip (1).Note:Mark fuse rating and
position for reinstallment. Pull locking slide (2) out of fuse
strip until stop is felt. Using special tool 61 1 136 or 61 1 137
press the spring latch down (3) and pull the connector from the
housing.ECM Main Relay Connector Unlock wire flap (1) of connector
being removed. Using special tool 61 1 136 or 61 1 137 press the
spring latch down (2) and pull the connector from the
housing.125101125.bmp125101126.bmp125101127.bmp125101128.bmpMiscellaneous
Connectors23Breakout Boxes and ConnectorsWorkshop Exercises1.Using
instructor supplied practice harness and connectors, remove and
reinstall
con-nectorsfromatleast5differenttypesofplugs.Recordplugtypeandtoolnumberoftool
used.2.Vehicle Model:Remove Pin #19 from X7003:What effect would
this have on transmission operation:3.Vehicle Model:Remove Pin #25
from connector X12:Print the ST of connector X12:What is the
location of X12:What effect will the removal of this pin
produce:4.Vehicle Model:Remove connector X165:What is the purpose
of X165:What are the page numbers used to located X165 (2):What is
the page number of the ETM containing X165:What effect will the
removal of this connector produce:24Breakout Boxes and
Connectors5.Vehicle Model:Remove Pin#26 from connector X256:What is
the location of X256:What is the purpose of Pin#26:Print the EO and
ST for Pin#26:Classroom discussion:Notes:25Breakout Boxes and
ConnectorsSOLDERLESS TERMINALS AND CONNECTORSMechanical strength of
solderless terminal design and electrical conductivity must be
main-tained at all times. To ensure these characteristics are
maintained in the vehicles electricalsystem several BMW repair kits
are available.The repair kits listed contain all the approved
connectors,pins, and tools required for prop-er repair of
BMW'selectrical, electronics com-ponents. Electrical Repair Kit
IVP/N 90 88 6 619 020TheElectricalRepairKitIV(Ref.SI.041892)isused
in conjunction with theinstruction
manualsanddetailedrepairmanualproceduresfromGroup61,Sub-group13foundinTIS.Theseprocedures
include: Disassembling, replacing a plug connection on the various
types of connectors. Cutting cable to length. Crimping stop parts
(Contacts). Butt connectors for repairing a plug
connection.Operating instructions for special tools and the
handling of individual parts in the repair kitare available under
PN 61 9 029.Three previous kits issued by BMW are: Electrical
Repair Kit I (Black Case)P/N 81 24 9 408 080 Electrical Repair Kit
II (Blue Case)P/N 81 24 9 408 300 Electrical Repair Kit III (Red
Case)P/N 82 11 9 408
400ElectricalrepairkitsI,IIandIIIareprimarilyneededforrepairingwiringharnessandcon-nectors
of older vehicles (E30 and earlier). Referto repair kit
instructions, SI bulletins and repairmanual microfiche.Operating
instructions for special tools in thesekits are available under PN
61 8 084.12510192.bmp12510193.bmp26Breakout Boxes and
ConnectorsElectrical Repair Kit
IVTheElectricalRepairKits(I,II,IIIandIV)havegone through various
upgrades.Electrical Repair Kit IV (PN 90 88 619 020)
hasbeendevelopedtohandlerepairsofthespe-cialized state of the art
wiring and harnesses ofthe newest BMW products. Cable
StripperSpecial Tool 61 9 043 Cable stripper with wirecutter for
cutting and stripping insulation fromcables.Crimping ToolSpecial
Tool 61 9 041 Crimping Tool with spe-cialtool619044
(matrix)forcrimpingcableguide and strain relief device on antenna
elbowplug.
Caution:ThespecialtoolscontainedintheElectricalRepairKits I,II,III
are not state of the art and are not suitablefor specialized wiring
harness
repairs.UseexclusivelyElectricalRepairKitIVforthoserepairs.Electrical
Repair Kit IV (61 9 020)Contains the following:61 9 041 Crimping
Tool61 9 042 Matrix61 9 043 Cable Stripper61 9 044 MatrixAssorted
Individual
Parts12510192.bmp125101210.bmp125101214.bmpSupplementarykitsforElectricalRepairKitIVarereleasedperiodicly.CheckthelatestServiceBulletintoinsureinformationonlatestconnectorsareavail-able.27Breakout
Boxes and ConnectorsCable
StrippingProperwirestrippingandconnectorreplace-ment is essential
to ensure the integrity of
theelectricalconnection.AlwaysfollowspecificinstructionsintheElectricalRepairKitIVinstructionmanualaswellasGroup61-13repair
manual found in the TIS. The length of wire to be stripped is
determinedby the wire
gauge.Properuseofthewirestrippingtoolwillpro-videconsistentlypositiveresults.Insertthewire(1)intothestripper.Stopthewirewhentherequiredstriplengthispastthecutter(2).Squeeze
the handle of the tool.When the top jaw of the tool touches the
wire(3) the mechanism shifts the clamping actionto a pulling action
which strips the wire of theinsulation
(4).125101211.bmp125101212.bmp125101213.bmp125101229.bmp28Breakout
Boxes and ConnectorsCrimping ToolUse the wire crimper from the BMW
ElectricalRepairKit.ThiscrimperisdesignedforthespecificconnectorsfoundinBMWautomo-biles.Proper
use of the tools will provide con-sistent good quality connector
crimps.The crimper is designed to apply just the
rightamountofpressurebasedonthewiregaugeand connector size.The tool
has removable crimper jaws (3). Thisfeature allows for an unlimited
number of con-nector types for future compatibility. The
repairmanualreferstothedifferentsizedcrimpingslots as Nests. The
gauge of the wire beingcrimped determines which Nest is
used.Example:A .75 - 1.0mm gauge wire requires nest 2 forproper
crimping.Throughout the Electrical Repair Kit
instructionmanualareillustrationsofvariousconnectorsbeing
crimped.The highlighted box of the 16box grid in these
illustrations refers to the
stor-agecompartmentintheelectricalkitdrawersin which that specific
connector can be found.Insert the crimping end of the connector
intotheappropriatenest.Illustrationprovidesexampleofcombreplacementconnector(4)and
inline splice connector
(5).125101215.bmp125101216.bmp125101217.bmpNestWire Cross-section
size1 0.035....0.50mm22 0.75......1.0mm23 1.5mm24 2.5mm229Breakout
Boxes and ConnectorsSqueeze the tool handle slightly to set the
toolin the first ratchet latch position.This will
holdtheconnectorinthetoolwithoutclosingthecrimp
(6).Insertthestrippedwireintothereceivingendofthecrimpertoolmakingsurethewireisinserted
far enough to ensure that only the
wireinsulationwillbeinsidetheinsulationsupportbarrel
(7).Properlycrimpedconnectorsexhibitthefol-lowing characteristics:
Theinsulationsupportbarrelwillbecrimped consistently and snug
against theinsulation.Theinsulationwillnotbecrushed (8). A
bellmouth crimp will be visible at the wireend of the of the wire
barrel (9). Wirestrandswillbevisibleatthecontactend of the wire
barrel (10). Insulation end will be visible in this area(11) (Fig.
27/1).The following are examples of unacceptable crimps: (Fig.
27/2) Excessive or no wire strands at the contact end of the wire
barrel (10).Excessive or no insulation end in the acceptable area
(11).125101222a.bmp 125101220a.bmp125101218.bmp125101219.bmpFig.
27/1Fig. 27/230Breakout Boxes and ConnectorsPrepackaged Wiring
Repair SetsIncludedwiththetheElectricalRepairKitIVare a variety of
wiring repair sets.These setscontain various pre-crimped wiring
connectorsonassortedgaugewirelengthsforsimplesplice connection
repair into a wiring harness.The repair kits also contain:1.
Various gauge lengths of wire with pre-crimped connectors.2.
In-line splice connectors.3. Heat shrink tubing.When used correctly
the in-line splice
connec-torsprovideaBMWfactoryapprovedwirecrimp.Use the correct size
nest in the crimpertool and connect one side of the in-line
crimpwith the wire.Slide a piece of heat shrink tubing on the
wireand crimp the other side of the in-line connec-tor.Use a heat
gun to shrink the tube around
thespliceconnectortoprovideamoistureresis-tant seal.Part numbers
for the wire sets or any compo-nent of all four electrical repair
kits can be re-ordered from: The P/N reference card inside each
repair kit. Special tools microfiche. The Electrical Repair Kit 1-4
componentcatalog (SD
92-036).Asnewconnectorsaredevelopedfornewvehicles,therepairkitswillbeannouncedbyService
Information bulletins and sent to dealerships via automatic tools
shipment.125101224.bmp125101226.bmp125101227.bmp31Breakout Boxes
and ConnectorsSoldering
ConnectionsIntheeventthatawiringconnectionmustbesolderedinavehicleselectricalsystem,therearecertainprocedureswhichmustbefol-lowed.Impropersolderingwillresultinpoorelectricalconnectionsordamagetoelectricalcomponents.SAFETY:
Adhere to the following basic guide-lines when preparing to solder.
Safety glasses must be worn.Disconnect vehicle battery. Cover
vehicle trim surfaces.Exercise your common sense. Provide adequate
ventilation, its the bestsafety precaution!Soldering Preparation
and Procedure
Thewireinsulationmustbestrippedtoexposeanadequateamountofbarewire(not
too little-not to much.) Thewiresandorconnectorsmustbeclean and
free of grease, dirt, wax, etc. Athincoatingofrosincoreflux
mustbeapplied to the soldering connection. Have enough 60/40
(tin/lead) general electrical solder on hand prior to starting. If
heat transfer to a heat sensitive component is possible use heat
sinks. Use a soldering gun tip that is the right size for the
job.Do not use an overly large tipwhich could melt wire insulation
and block your view of what is being soldered. The soldering tip
must be tinned.This means to keep a thin layer of solder on thetip
at all times during soldering.This will transfer the heat quickly
and allow the solderto flow easily into the joint being soldered.
Preheat the wires or connector.Introduce the solder into the joint
not the soldering tip. When the solder starts to flow allow it to
infiltrate the joint only for a moment. Almostsimultaneously, pull
the tip off of the joint to prevent overheating. A properly
soldered joint will be smooth, shinny, and even
surfaced.125101230.bmp125101231.bmp32Breakout Boxes and
ConnectorsWorkshop Exercises1.Using instructor supplied practice
wiring and connectors, perform wire stripping on atleast three
different sizes of wire:Perform connector crimping on each of the
wires stripped:Have instructor inspect wire stripping and crimping
operations:2. (Optional exercise)Perform solder of wires and/or
connectors as instructed:Notes:33Breakout Boxes and
ConnectorsBreakout Boxes and V CablesBreakout Boxes are used to:
Provide a convenient tap into an electrical circuit. Minimize the
possibility of damage to control unit connections and wire
harnesses dur-ing diagnosis of electrical/electronic systems.
Ensure solid meter connections for proper diagnosis, this in turn
will help the technicianto be more organized and efficient. Provide
easier access to circuits for testing with equipment such as,
multimeter, DISplustester or other diagnostic tools.CAUTION:
Breakout box cable connections are universal in order to fit the
varying codedconnectors found in the vehicles.Always confirm that
you are connecting the correct con-trol module into the system
harness that is on the other side of the breakout box.Systemdamage
will occur if it is not the correct system.Example: DME and EGS/AGS
control modules both utilize an 88 or 134 pin control mod-ule.These
control modules reside in the same E-Box on most vehicles.The
control mod-ules are coded to prevent unintentional cross
connecting at the vehicle harness.But,
thisconnectorcodingisnotpresentonthe88or134pinbreakoutbox(s).Result:ADMEcontrol
module could be connected to a transmission control system. Damage
willresult!Several different types of breakout boxes are available
depending on the particular systembeing
diagnosed.MOTRONIC125101232.bmp34Breakout Boxes and Connectors55
pin Breakout Box P/N 81 12 9 425
091Usedwithcontrolmodulesthathavesinglemultipin plugs from 25 to 55
pins. L-jetronic ABS MotronicEGSAdapter cables are required.83 Pin
Breakout Box (Red Face)P/N 90 88 6 614 420
WhenusedwithABS/ASC5system,noadapter cables are required.See SIB 04
10 95aboutanadapterharnessforusewiththeTeves Mark IV G ABS system
of the E36.88 Pin Breakout Box (Green Face)P/N 88 88 6 614 410Used
with control units that have up to 88 pins; DME EGS/AGS ZAE/MRS
LCMNo adapter cables are required when connect-ed to a DME or
EGS/AGS control module.SeeSIBs042696 and041596aboutadapterharnesses
for ZAE/MRS and LCM systems.
125101243.bmp125101242.bmp125101243.bmp35Breakout boxes and
Connectors134 Pin SKE Control Module Breakout Box SetP/N 90 88 6
121 300The 134 pin modular connector DME and AGScontrol modules use
a combination of
breakoutboxesfortroubleshooting.Thepartnumberaboveprovidesthreebreakoutboxesandfiveadapterharnesses.Thetwooutsideedgeconnectorsusethefamiliar26pinbreakoutboxes.Thethreeinsideconnectorsusetheboxes
from the ordered set.26 Pin Breakout BoxP/n 88 88 6 611 459Used
with system or peripheral control modulethat have up to 26
pins.This breakout box isused in conjunction with adapter cables
called V Cables. There are many different types of V cables for the
various connectors found onthe vehicles.60 Pin Breakout BoxP/N 90
88 6 614 390Usedforconnectingalladapterleadswith27pin to 60 pin
plug connections.125101241.bmp125101236.bmp125101244.bmp36Breakout
Boxes and ConnectorsTester and Adapter Set for RelaysThe Relay
Adapter provides a platform to test arelay while allowing the relay
to remain active ina circuit.The adapters included enable different
pin con-figurations of relays to be tested using a singletester.
Removerelayandcomparepluginadapterwithplugpatternonrelay.Choosecorrectadapter
(Fig. 33/1).FitadaptertoMeasuringbridge,notingthemarker arrows (A).
Fit the relay to the measur-ing bridge (Fig.
33/2).Plugtheassemblemeasuringbridgeintothesocket of the relay to
be checked. Test using
amultimeter.Seethecircuitdiagram,testinginstructionsandrepairmanualforsubsequentprocedure
(Fig.
33/3).125101237.bmp125101238.bmp125101240.bmp125101239.bmpFig.
33/1Fig. 33/3 Fig. 33/237Breakout Boxes and ConnectorsV
CablesVcablesareavailableindifferentversionsdependingonthesystembeingdiagnosed.Always
refer to the most recent Service informa-tion for the required
special tools.V cables are only used with the 26 pin
break-outboxtoaccessinputandoutputsignalsofperipheral modules and
systems. The appropriate cable is distinguished by the color of the
connector end. The color will match the particular modules
connector color.Unless the color matches, thecable will not fit the
connector on the module being tested. Each colored V cable has a
series of alignment tabs that will only fit its particular mod-ule
or system.V cables with ELO connectors are also being used with the
26 pin breakout
box.Thesecablesareuniqueinthattheyhavealockingarmonthecomponentsideofthecable.Theyarelightgreenincolor,andthenumberofpinswillvarydependingonthesystembeing
tested.V harness adapters were introduced with the E38. These also
have light greenELO con-nectors on the component side, but they do
not require a breakout box.There is a black plug on one side with
same number of pins as the component being test-ed. The plug has
numbers stamped on its side that corresponds with the pins on that
partic-ular component.You access the signals by plugging the test
equipment directly into those pin numbers.As new systems and
components are being introduced, new breakout boxes and cableswill
also be introduced.
AlwaysremembertorefertothemostrecentserviceinformationinTISorServiceInformation
Bulletins for the latest diagnostic tools and
procedures.125101228.eps38Breakout Boxes and ConnectorsWorkshop
Exercises1.Vehicle model:Install SKE 134 pin Breakout box set:Which
connector numbers will connect to the 26 pin boxes:2.Vehicle
Model:Install the correct V cable at connector X257:What is the PN
of the correct V cable:What breakout box is used with this V
cable:What function of the vehicle are tested using the V cable and
breakout box:3.Vehicle Model:Install the correct V cable on the
LSZ:What is the PN of the V cable:4.Vehicle Model:Install the
correct Breakout box on A7000:What is the location of A7000:What is
the Breakout Box Pn used:Print the PB for A7000:5.Vehicle
Model:Install the Xeonon Light Test Cable:What SIB covers the
installation and use of this test cable:What is the PN for this
test cable:6.Vehicle Model:Connect the proper V cable to the DCS
control Module:What is the PN for the V cable:What is the PN for
the correct breakout box:7.Vehicle Model:Connect the Relay Adapter
for testing of the DME main relay:What is the location of the DME
main relay:Perform a voltage drop test on the work side of the DME
main relay with theengine running:Notes:39Breakout Boxes and
ConnectorsExamples of V cablesPart number Description Chassis Use61
1 260 30 Pin V cable E46 Wiring door harness61 1 270 24 Pin V Cable
E46 Connection on seat plug61 1 460 Set of 8 cables E32,36,38 Door
harness and others61 1 480 Set of 7 cables E30,32,34 Various
electrical systems61 1 490 Set of 2 cables E34 Engine wiring
harness61 2 050 2 Pin V cable (JPT) E31,32,34 Servotronic61 2
070Set of 3 cables E36,38,46, Electrical front seat61 3 030V cable
E38 DSC 3 control module61 3 150 54 Pin adapter E46 Light module61
3 190Test Leads E38,39 EWS61 3 210 5 Pin V cable E46 Seat heating61
3 220 8 Pin V cable E46 Power window and int light61 3 240 8 Pin V
cable E46 Door locks61 4 350 V cable E38,39,46 Center console
switch61 4 450 20 Pin V cable E30,31,36 LKM and EM convertible
top61 4 460 Set of 4 26 pin cables E31,34,36 Various electrical
systems61 6 020 Set of 6 cables E38 Various electrical systems61 6
030 Set of 5 cables E38 Various electrical systems61 6 040 Set of 5
cables E38 Various electrical systems61 6 050 6 Pin V cable E39,46
Various electrical systems40Breakout Boxes and ConnectorsPlug
Adapter Relay TesterPart Number Use61 3 013 Crash Sensor61 3 014
Hazard Warning System61 3 015 Hazard Warning System C261 3 017
Changeover Relay61 3 018 N/O (Normally Open) Relay61 3 019 Rear
Window Heater61 3 021 Windscreen Heater61 3 016 ABSAirbag
repairsAlways refer to the latest SIB for information pertaining to
the latestAirbag repair procedures.SIB 61 02 00Important Notes
Concerning Airbag RepairsOnly repair those cables which show
visible signs of damage. If there is visible damage, make sure
thatonly one cable repair is present after repairing. If no visible
damage can be identified, the entire cablemust be replaced. When
carrying out repairs to the airbag wiring harness use only those
parts specifiedin the EPC as Airbag Repair Cable.41Breakout Boxes
and ConnectorsReview Questions1.Under what Group Number and Sub
Group Number would you find instruction manuals and detailed repair
procedures concerning Electrical Repair Kit IV?2. Special Tool 61 1
138 Instrument ClusterIllumination Tool can be found in what
spe-cial tool kit?3. Which Circular Connector Lock Disengaging Tool
would be used on a Circular connector with 10 pins?4. What does JPT
ELA refer to?5. When stripping a wire with a cross-section size of
.50m2, what should the stripped length be?6. Which nest on the
crimping tool would be used to crimp a wire with cross-section of
.80m2.7. Prepackaged Wiring repair sets contain?8. Why must a
soldering tip be tinned?9. What are the face colors or highlights
on the following BOB?90 88 6 614 420 How many Pins?88 88 6 614 410
How many Pins?10. Under what SIB number could you find information
concerning adapter cable when using BOB 90 88 6 614 420 ?11. What
BOB uses V cables to access input and output signals?12. What is
SKE?13. What special tool should be used to check the proper
operation of a relay?14. What is the proper procedure for removing
the contacts from the contact carrier onElo type connectors and
those manufactured by AMP?